ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 4

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System 

# A Rockdale Oper ations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2005 Page 1 of 6

Title: Control Plan for Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/9/2004 6/8/2004 2/6/2003 2/5/2003 9:08 AM 1:35 PM 3:41 PM 1:57

PM 1:25 PM 12:59 PM 12:23 PM Special Hazards: FAILURE TO FOLLOW PROCEDURES CORRECTLY AND MAINTAIN

PROPER EQIPMENT PARAMETRICS MAY RESULT IN EQUIPMENT

DAMAGE AND/OR A MACT PARAMETRIC EXCEEDANCE.

Significant

Environmental

Aspect: Following this procedure w ill ensure that proper steps are taken to decrease adverse

impacts to the environment.

PREPARATION

TAG & LOCK

TRY . ALWAYS FOLLOW THE PROPER TAG, LOCK AND TRY PROCEDURE

WHEN PERFORMING MAINTENANCE REPAIRS AND/OR

REPLACEMEN TS WHERE APPLICABLE.

CONFINED SPACE: . ALWAYS FOLLOW THE PROPER CONFINE SPACE ENTRY PROCEDURE

WHEN PERFORMING MAINTENANCE REPAIRS AND/OR

REPLACEMENTS WHERE APPLICABLE.ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 4

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System 

# A Rockdale Oper ations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2005 Page 2 of 6

Title: Control Plan for Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/9/2004 6/8/2004 2/6/2003 2/5/2003 9:08 AM 1:35 PM 3:41 PM 1:57

PM 1:25 PM 12:59 PM 12:23 PM PROCEDURE TO:

Control Fan Amps

Water Flow

ESP’s

Outlet Emissions

Dust Coll ecting Hoppers NOTE: All Potroom Fume Control MACT parametric alarms must be acknowledged

within one hour of the time the alarm was initiated. All MACT exceedances and

malfunctions must be reported and documented within one hour of the initial

identification. If any inspections and/or repairs are to be made, use all required tag,

lock, try and confine space entry procedures

where applicable.



### Fan Amps (MACT Parameter)

Operating Range ESP’S

. Minimum 129 Amps, Normal 161 Amps

Operating Range 13D1

. Minimum 177 Amps, Normal 222 Amps

Measurement Method

. Amp signal is indicated on computer control screen (Wonderware) and on a field

display (Panelview and analog meter)

. MACT compliance data values are indicated on computer screen (Access) and

values and trends are indicated on computer control screen (Wonderware).

Control Method

. Ensure fan damper is positioned for proper MACT parametric requirements.

Consequences of Deviation

. Below minimum parametrics can cause low potdraft, high potline roof emissions

and MACT parametric exceedances.

Corrective Action

. Exercise or open damper to keep within required MACT parametric values.

Report problems to supervision. R efer to MACT Reaction Plan SOP’s for required

fan amps. If control device is below MACT compliance start another or an

additional fan(s).



### Water Flow (MACT Parameter) And pH Level

GPM Operating Range ESP’S

. Minimum 176 GPM, Normal 220 GPM

GPM Operating Range 13D1

. Minimum 188 GPM, Normal 235 GPM

pH Operating Range

. 8

- 10 at basin, 10

- 12 at clearwellROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 4

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System 

# A Rockdale Oper ations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2005 Page 3 of 6

Title: Control Plan for Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/9/2004 6/8/2004 2/6/2003 2/5/2003 9:08 AM 1:35 PM 3:41 PM 1:57

PM 1:25 PM 12:59 PM 12:23 PM PROCEDURE TO:

Control Fan Amps

Water Flow

ESP’s

Outlet Emissions

Dust Collecting Hoppers

(continued) Measurement Method

. GPM signal is indicated on computer control screen (Wonderwa re) and on a

field display (Panelview and Panametric meter). PH signal is indicated on

computer control screen (Wonderware) and field pH meter.

. MACT Compliance data values are indicated on computer screen (Access) and

values and tren ds are indicated on computer control screen (Wonderware).

Control Method

. Ensure water valves are positioned for proper MACT parametric requirements.

Ensure correct amounts of lime for proper pH levels.

Consequences of Deviation

. Below m inimum parametrics can cause high outlet emissions and MACT

parametric exceedances. High and low levels of pH can cause inadequate

scrubbing and excess solids which leads to build

- up.

Corrective Action

. Excersise or open header valves to keep within required MACT parametric

values.

Always leave the main valve fully open. Report problems to supervision. Refer

to MACT Reaction Plan SOP’s for required fan amps. If control device is

below MACT compliance start anot her or an additional scrubber(s). Monitor

lime slaker operation and controls.



### ESP Primary Voltage (MACT Parameter)

Operating Range

. Minimum 140 Volts, No Normal

Measurement Method

. Volt signal is indicated on computer control screen (Wonderware), on a field

BHA controller and an analog meter.

. MACT Compliance data values are indicated on computer screen (Access) and

values and trends are indicated on computer control screen (Wonderware).

Co ntrol Method

. Ensure precipitator is on and primary voltage is above the required MACT

parametric minimum.

Consequences of Deviation

. Below minimum parametrics can cause high outlet emissions and MACT

parametric exceedances.ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 4

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System 

# A Rockdale Oper ations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2005 Page 4 of 6

Title: Control Plan for Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/9/2004 6/8/2004 2/6/2003 2/5/2003 9:08 AM 1:35 PM 3:41 PM 1:57

PM 1:25 PM 12:59 PM 12:23 PMROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 4

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System 

# A Rockdale Oper ations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2005 Page 5 of 6

Title: Control Plan for Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/9/2004 6/8/2004 2/6/2003 2/5/2003 9:08 AM 1:35 PM 3:41 PM 1:57

PM 1:25 PM 12:59 PM 12:23 PM PROCEDURE TO:

Control Fan Amps

Water Flow

ESP’s

Outlet Emissions

Dust Collecting Hoppers

(conti nued) Corrective Action

. Ensure dust collecting hoppers to be empty and call supervision to have

cleaned. If below minimum is still present call supervision for an I@E

technician. If control device is below MACT compliance start another or an

additional precipitator(s).



### ESP Primar y Voltage (MACT Parameter)

Operating Range

. 1 4 0 Volts , No Normal



### ESP Secondary Current (MACT Parameter)

Operating Range

. Minimum 10 mAMPS, No 9.66 mAmps, No Normal

Measurement Method

. Milliamp signal is indicated on computer control screen (Wonderware), on a

field BHA controller and an analog meter.

. MACT Compliance data values are indicated on computer screen (Access) and

values and trends are indicated on computer control screen (Wonderware).

Control Method

. Ensure precipitator is on and secondary current is above the required MACT

parametric minimum.

Consequences of Deviation

. Below minimum parametrics can cause high outlet emissions and MACT

parametric exceedances.

Corrective Action

. Ensure dust collecting hoppers to be empty and call supervision to have

clean ed. If below minimum is still present call supervision for an I@E

technician. If control device is below MACT compliance start another or an

additional precipitator(s).



### Outlet Emissions

Operating Ran ge

. Dry and white to off

- white color.

Measurement Method

. Daily visible inspection per SOP.

Control Method

. Initiate corrective action per SOP. Ensure water GPM to not be above set

maximum value. Ensure ESP to be in operation with pri mary voltage and

secondary current above the MACT parametric minimum. Ensure 13D1bag

drops to be normal and dirty bag detector to be below 100.ROCKDALE OPERATIONS

- SMELTING AND INGOT PAGE 1 OF 4

Document Number: PMT

- SOP

- 2005

Title: Control Plan For Line 3 Wet Scrubber System 

# A Rockdale Oper ations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2005 Page 6 of 6

Title: Control Plan for Line 3 Wet Scrubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/9/2004 6/8/2004 2/6/2003 2/5/2003 9:08 AM 1:35 PM 3:41 PM 1:57

PM 1:25 PM 12:59 PM 12:23 PM Consequences of Deviation

. Abnormal emissions is an indication high gaseous and/or particulates.

Corrective Action

. Initiate corrective action. Refer to MACT Reaction Plan SOP for visible

emissions.



### Dust Collecting Hoppers

Operating Range

. Empty or near empty.

Measurement Method

. Manual tapping everyday and ensuring proper hopper cont rols and dust

collection.

Control Method

. DPU system operating for ESP’s.

Consequences of Deviation

. Dust backs up into ESP direct current power wires and plates causing a short

which leads to low parametric values causing high outlet emissions and MACT

parametric exceedances.

Corrective Action

. Ensure dust collecting hoppers to be empty and call supervision to have cleaned. PROCEDURE TO:

Control Fan Amps

Water Flow

ESP’s

Outlet Emissions

Dust Collecting Hoppers

(continued)